Duct cover

ABSTRACT

A temporary duct cover for use in an HVAC installation processes. The temporary duct cover having a filtration portion and a closure member. The filtration portion being made from material which is air and water permeable. The closure member being configured to conform a duct. The temporary duct cover minimizes particulate infiltration to the duct while allowing moisture to escape from the duct, thereby inhibiting mold or mildew from forming in the duct.

FIELD OF THE INVENTION

The present invention is directed to duct covers. More specifically, thepresent invention is directed to protective duct covers which reducesthe amount of contaminates that enter duct work during construction andthe like, while allowing trapped moisture to escape from the ducts toreduce the likelihood of mold or mildew growth in the ducts.

BACKGROUND OF THE INVENTION

Air handling units and controls for heating, ventilation and airconditioning (HVAC) are expensive and sensitive to outside contaminants,such as, but not limited to, dirt, dust and other debris. Neglecting tocover ducts and equipment during the installation process of an HVACsystem can result in a contaminated system that requires cleaning orpossible water damage that requires replacement.

During construction of a structure or the like, the ductwork is usuallyinstalled after the building is framed, but not yet completed.Therefore, the ducts are usually installed long before the HVAC unititself is installed and connected. Consequently, in order to avoidcontaminants accumulating in the ducts, it is useful to cover the endsof the ducts to inhibit the entrance of the contaminants.

To keep debris, rain or any other contaminants from the ducts whichprotrude through a roof installation, poly plastic sheeting is oftenplaced on the duct openings and secured with duct tape. Poly plastic isalso commonly duct taped around duct openings in the interior ofbuildings. This process is cumbersome, time-consuming and often requirestwo people.

Other types of coverings are known, such as described in U.S. Pat. No.6,874,541, which discloses a temporary duct cover. The duct coverincludes a cover envelop having a body, the body having an open end andan opposed closed end with a center portion extending between the openend and the closed end to define an envelope enclosure, the body beingmade of suitable particle-proof and waterproof material, such as polyplastic, and an elastic member being operably coupled to the body openend and having a relaxed disposition, an expanded disposition, and aduct conforming disposition in compressive sealing engagement with theduct exterior margin.

As described, plastic is used to create a waterproof barrier thatprevents airborne contaminants, moisture, and water from entering intothe system. However, plastic also prohibits trapped moisture and waterfrom escaping, which can result in the growth of mold or mildew.

It would, therefore, be beneficial to provide duct cover whicheliminates the problems with the prior art, and which provides atemporary breathable duct and equipment cover for use during therough-in stage of an HVAC system. The product inhibits dust and debrisfrom entering the open duct during construction. It will also allow forthe transfer of air in order to allow moisture to escape and to reducethe occurrence of mold and/or mildew. Consumers will appreciate theefficiency that this product affords.

SUMMARY OF THE INVENTION

In one embodiment of the invention, the duct cover provides a temporarybreathable duct and equipment cover for use during the rough-in stage ofan HVAC system.

In another embodiment of the invention, the duct cover inhibits dust anddebris from entering the open duct during construction while allowingfor the transfer of air in order to allow moisture to escape and toreduce the occurrence of mold and/or mildew.

An embodiment is directed to a temporary duct cover for use in an HVACinstallation processes. The temporary duct cover having a filtrationportion and a closure member. The filtration portion being made frommaterial which is air and water permeable. The closure member beingconfigured to conform a duct or equipment. The temporary duct coverminimizes particulate infiltration to the duct while allowing moistureto escape from the duct, thereby reducing the likelihood of mold fromforming in the duct.

An embodiment is directed to a duct cover having a filtration portionand a closure member. The filtration portion is made from material whichrestricts the ingress of particulates into a duct, retards the ingressof moisture into the duct and allows the egress of moisture from theduct to reduce the formation of mold or mildew in the duct. Thefiltration portion has an open end and a closed end. The closure member,which is configured to conform to the duct, is provided at the open endof the filtration portion.

An embodiment is directed to a duct cover having a filtration portionmade from material which inhibits particulates larger than 100 micronsfrom passing through the filtration portion and the temporary ductcover. The material having values of greater than approximately 500 g ofbreathability and values of less than approximately 20,000 mm of waterresistance.

Other features and advantages of the present invention will be apparentfrom the following more detailed description of the preferredembodiment, taken in conjunction with the accompanying drawings whichillustrate, by way of example, the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an exemplary duct over which a cover ofthe present invention may be disposed;

FIG. 2 is a perspective view of the cover of FIG. 1 which is notdisposed on the duct;

FIG. 3 is a side view of the cover disposed on the section of the ductshown in FIG. 1, the cover is shown to be transparent to allow the endof the duct to be shown;

FIG. 4 is a perspective view of a first alternate exemplary embodimentof a cover; and

FIG. 5 is a perspective view of a second alternate exemplary embodimentof a cover.

DETAILED DESCRIPTION OF THE INVENTION

An exemplary embodiment of the present invention is a cover 10 made of asuitable material to inhibit dust, debris, and/or other materials fromentering ducts 12 or other equipment, such as, but not limited to ductsor equipment relating to HVAC systems. The cover 10 is configured suchthat a portion of the cover conforms to the shape of the duct 12 overwhich it is placed on.

In one exemplary embodiment, the cover is made from a spunbondpolypropylene material with a closure member 14, such as, but notlimited to an elasticized hem, draw string or hook and loop closure.Alternately, the cover may be made from other materials, such as but notlimited to flash spun high-density polyethylene fibers or bilaminatefabric or materials. The type of fabric used will determine thefiltration (pour size), water resistance capabilities and the watervapor transmission (breathability) of the cover 10. The cover may beoffered in different styles and sizes to accommodate the user's needsand the size of the ducts 12. The ducts 12 may be round or rectangularand range from 4 inches to 20 inches or larger. Examples of sizes forthe cover include, but are not limited to: small circular, approximately6 inches—approximately 14 inches diameter or circumference ofapproximately 44 inches; medium circular, approximately 14inches—approximately 26 inches diameter or circumference ofapproximately 81 inches; large circular, approximately 26inches—approximately 40 inches diameter or circumference ofapproximately 125 inches; extra large circular, approximately 40inches—approximately 54 inches diameter or circumference ofapproximately 169 inches; 2X large circular, approximately 54inches—approximately 70 inches diameter or circumference ofapproximately 220 inches; 3X large circular, approximately 70inches—approximately 90 inches diameter or circumference ofapproximately 282 inches; medium oval, approximately 14inches—approximately 26 inches width by approximately 54inches—approximately 70 inches length or circumference of approximately165 inches; and large oval, approximately 26 inches—approximately 40inches width by approximately 70 inches—approximately 90 inches lengthor circumference of approximately 218 inches. Other sizes can be madeper specification.

As shown in FIGS. 2 and 3, the cover 10 has a closure member 14 and afiltration portion 16. In the exemplary embodiment shown, the filtrationportion 16 has a general shape of a hair net with an open end 18 and anopposed closed end 20. A circumferentially extending sidewall 22 extendsbetween the open end 18 and the closed end 20. In the exemplaryembodiment, the filtration portion 16 is air and water permeable and isa spun bond polypropylene material. However, other materials such as,but not limited to, flash spun high-density polyethylene fibers orbilaminate fabrics may be used without departing from the scope of theinvention. Examples of commercially available material, includes, but isnot limited to, OXCO Dura 150 White, OXCO SMS, TYVEK 2461 RV, TYVEK1460, and TYVEK Metallized, the properties of which are herebyincorporated by reference. Any material used must have the filtrationcharacteristics (pour size), water resistance capabilities and the watervapor transmission capabilities (breathability) required to allow forthe desired filtration of the dust, debris, and/or other materials andthe desired breathability to allow moisture to escape from the ducts. Asthe material is water resistant, the material delays water penetration;it does not prevent the water penetration.

In one exemplary embodiment, the filtration portion 16 may be made frommaterial or fabric which inhibits particulates larger than approximately100 microns from passing through the filtration portion 16 and the cover10. In a first alternate exemplary embodiment, the filtration portion 16may be made from material or fabric which inhibits particulates largerthan approximately 25 microns from passing through the filtrationportion 16 and the cover 10. In a second alternate exemplary embodiment,the filtration portion 16 may be made from material or fabric whichinhibits particulates larger than approximately 10 microns from passingthrough the filtration portion 16 and the cover 10. In a third alternateexemplary embodiment, the filtration portion 16 may be made frommaterial or fabric which inhibits particulates larger than approximately1 micron from passing through the filtration portion 16 and the cover10.

As stated above, the filtration portion 16 has water resistantcapabilities and water vapor transmission capabilities (breathability).Such water resistant/breathable fabrics resist liquid water passingthrough, but allow water vapor to pass through. Generally, waterresistance is measured by the amount of water, in mm, which can besuspended above the fabric before water seeps through. Breathability orwater/moisture vapor transmission rate is measured by the rate at whichwater vapor passes through, in grams of water vapor per square meter offabric per 24 hour period (g/m²/d), often abbreviated to just “g”.

In an exemplary embodiment, the material or fabric of the filtrationportion 16 has values of greater than approximately 750 mm of waterresistance. In another exemplary embodiment, the material or fabric hasvalues of less than approximately 20,000 mm of water resistance. Inanother exemplary embodiment, the material or fabric has values of lessthan approximately 15,000 mm of water resistance. In another exemplaryembodiment, the material or fabric has values of less than approximately10,000 mm of water resistance. In another exemplary embodiment, thematerial or fabric has values of less than approximately 5,000 mm ofwater resistance. In another exemplary embodiment, the material orfabric has values of less than approximately 1,000 mm of waterresistance. In another exemplary embodiment, the material or fabric hasvalues of less than approximately 500 mm of water resistance. In anotherexemplary embodiment, the material or fabric has values of less thanapproximately 15,000 mm of water resistance and greater than 2,000 mm ofwater resistance. In another exemplary embodiment, the material orfabric has values of less than approximately 8,000 mm of waterresistance and greater than 3,000 mm of water resistance. However,depending upon the environment in which the cover 10 is used, the valuesof water resistance may be less meaningful, i.e. in indoor environmentsin which the cover 10 is not subjected to significant rain or otherliquid engagement. Therefore, the values of water resistance may falloutside of these ranges without departing from the scope of theinvention.

In an exemplary embodiment, the material or fabric of the filtrationportion 16 has values of greater than approximately 500 g ofbreathability or moisture vapor transmission rate. In another exemplaryembodiment, the material or fabric has values of greater thanapproximately 1,000 g of breathability. In another exemplary embodiment,the material or fabric has values of greater than approximately 5,000 gof breathability. In another exemplary embodiment, the material orfabric has values of greater than approximately 10,000 g ofbreathability. In another exemplary embodiment, the material or fabrichas values of greater than approximately 15,000 g of breathability. Inanother exemplary embodiment, the material or fabric has values of lessthan approximately 20,000 g of breathability and greater than 5,000 g ofbreathability. In another exemplary embodiment, the material or fabrichas values of less than approximately 18,000 g of breathability andgreater than 10,000 g of breathability. However, the breathability isvery dependent upon weather conditions, especially temperature andhumidity, and therefore, the breathability of the material or fabric mayfall outside of these ranges without departing from the scope of theinvention.

The values of water resistance and breathability are optimized based onthe environment in which the cover 10 is to be used to: i) retard theingress of moisture into the duct; ii) allow the egress for moisturefrom the duct to inhibit the formation of mold or mildew in the duct;iii) while maintaining a cost effective price for the cover 10.

Light transmissivity of the filtration portion 16 is not typically animportant feature and accordingly, the filtration portion 16 may beclear or opaque as desired.

As shown in FIGS. 2 and 3, the filtration portion 16 has a lengthdimension L (FIG. 3) measured from the open end 18 to the closed end 20.The open end 18 has a rough or approximate diameter D1 when the open end18 is formed in a generally circular shape and is in a first or anunstressed position. The rough or approximate diameter D2 of the centerportion between the open end 18 and the closed end 20 is greater thanthe diameter D1. The diameter D3 of the duct 12 on which the temporaryduct cover 10 is to be installed is less than the diameter D2 of thecenter portion.

The closure member 14 is positioned at the open end 18 of the cover 10.The closure member 14 may be fastened to the closure member 14 in anysuitable manner using known techniques, such as, but not limited to,sewing or bonding.

If the closure member 14 is an elasticized hem or the like, as shown inFIGS. 1 through 3, the unstressed diameter D1 of the open end 18 will beless than the diameter D3 of the duct 12. However, the closure member 14can be elastically expanded or stretched to allow the diameter D1 of theopen end 18 to be larger than the diameter D3 of the duct 12, therebyallowing the open end 18 to be inserted over the duct 12. The elasticclosure member 14 has sufficient resilience and flexibility to attemptto return toward its unstressed position to tightly conform the open end18 to the duct 12 on which the cover 10 is installed when the elasticclosure member 14 is released from its fully expanded stretched positionand is permitted to contract about the duct 12 in a duct confirmingdisposition, as shown in FIG. 3.

With respect to the exemplary embodiment having an elastic hem, inoperation, a user stretches open the elastic closure member 14 andslides the open end 18 over the duct 12. In one exemplary embodiment,insertion may continue until the closed end 20 of the filtration portion16 is generally snug on the opening of the duct 12. However, wheninserted the cover 10 on the duct 12, the insertion of the open end 18may be stopped at different locations along the duct 12. Therefore, theclosed end 20 is not always provided in contact with the end of the duct12. The elastic closure member 14 is then released and the closuremember 14 conforms to the duct 12 in compressive, sealing engagement.The elasticity and the positioning of the open end 18 away from the openend of the duct 12 facilitates keeping the cover 10 in sealingengagement with the duct 12 even should the duct 12 have a slight overpressure with respect to ambient conditions.

If the closure member 14 is a draw string (FIG. 4), hook and loop strips(FIG. 5) or the like, the initial diameter D1 of the open end 18 will belikely be greater than the diameter D3 of the duct 12, thereby allowingthe open end 18 to be inserted over the duct 12. The closure member 14is configured to contract about the duct 12 when manipulated by a useror the like to tightly conform the open end 18 to the duct 12 on whichthe cover 10 is installed.

With respect to the exemplary embodiment having a draw string, hook andloop strips, in operation, a user slides the open end 18 over the duct12. In one exemplary embodiment, insertion may continue until the closedend 20 of the filtration portion 16 is generally snug on the opening ofthe duct 12. However, when inserted the cover 10 on the duct 12, theinsertion of the open end 18 may be stopped at different locations alongthe duct 12. Therefore, the closed end 20 is not always provided incontact with the end of the duct 12. The closure member 14 is thentightened to conform the closure member 14 and the open end 18 to theduct 12 in sealing engagement. The forces associated with tightening theclosure member 14 and the positioning of the open end 18 away from theopen end of the duct 12 facilitates keeping the cover 10 in sealingengagement with the duct 12 even should the duct 12 have a slight overpressure with respect to ambient conditions.

The duct and/or equipment cover as described herein provides consumerswith a breathable cover to inhibit dust and debris from entering openducts, such as HVAC ducts, and equipment during construction. However,because of the breathability of the filtration portion 16 of the cover,moisture and water vapor may escape from the duct 12 even when the cover10 is provided in engagement with the duct 12. It is often the caseduring construction that moisture will accumulate in the newly installedducts. This is particularly true in areas with high humidity. Ifwaterproof covers are positioned over the openings of the ducts, airflow in the ducts is prevented and the moisture trapped in the ductsstagnates and causes mold. As the current invention described herein ismade from breathable material or fabric, moisture initially trapped inthe duct can escape, reducing the likelihood of mold or mildew fromforming in the duct.

The closure member, whether it is an elasticized hem, draw string, hookand loop fasteners or other type of closure allows for a snug fit aroundthe duct or equipment. These covers are easy and fast to install. Thecovers may be washed and reused if proper care is exercised. No tapes oradhesives are required. The duct and equipment cover styles all includebreathability for water vapor transmission and include dust, debris andwater resistance characteristics. These characteristics will varydepending on the type and style of material used. These covers aredesigned for interior use that are subject to minimal or noprecipitation or direct contact with unprotected weather elements.

Alternative embodiments of the cover may include a waterproof center ortop in conjunction with the spunbond polypropylene, flash spunhigh-density polyethylene fibers or bilaminate breathable outer sideswhich may be used for covering a duct or equipment that is in directcontact with the outdoor elements. The center or top of the cover wouldprevent water, dust and debris from entering into the covered product.The sides would be water resistant and breathable allowing the water toshed down off the water proof center. This would allow the cover towithstand infiltration of water with the capability of the breathableside material allowing the transfer of air so as not to trap moistureunder the protective cover.

While the invention has been described with reference to a preferredembodiment, it will be understood by those skilled in the art thatvarious changes may be made and equivalents may be substituted forelements thereof without departing from the scope of the invention. Inaddition, many modifications may be made to adapt a particular situationor material to the teachings of the invention without departing from theessential scope thereof. Therefore, it is intended that the inventionnot be limited to the particular embodiment disclosed as the best modecontemplated for carrying out this invention, but that the inventionwill include all embodiments falling within the scope of the appendedclaims.

1. An temporary duct cover for use in an HVAC installation processes,the temporary duct cover comprising: a filtration portion, thefiltration portion made from material which is air and water permeable;a closure member which is configured to conform to a duct; wherein thetemporary duct cover minimizes particulate infiltration to the ductwhile allowing moisture to escape from the duct, thereby inhibiting moldor mildew from forming in the duct.
 2. The temporary duct cover asrecited in claim 1, wherein the filtration portion is made from spunbondpolypropylene.
 3. The temporary duct cover as recited in claim 1,wherein the filtration portion is made from flash spun high-densitypolyethylene fibers.
 4. The temporary duct cover as recited in claim 1,wherein the filtration portion is made from bilaminate materials.
 5. Thetemporary duct cover as recited in claim 1, wherein the filtrationportion is made from fabric which inhibits particulates larger than 100microns from passing through the filtration portion and the temporaryduct cover.
 6. The temporary duct cover as recited in claim 5, whereinthe fabric inhibits particulates larger the 25 microns from passingthrough the filtration portion and the temporary duct cover.
 7. Thetemporary duct cover as recited in claim 6, wherein the fabric inhibitsparticulates larger the 10 microns from passing through the filtrationportion and the temporary duct cover.
 8. The temporary duct cover asrecited in claim 7, wherein the fabric inhibits particulates larger the1 micron from passing through the filtration portion and the temporaryduct cover.
 9. The temporary duct cover as recited in claim 1, whereinthe closure member is made from elasticized hem.
 10. The temporary ductcover as recited in claim 1, wherein the closure member is made from adraw string.
 11. The temporary duct cover as recited in claim 1, whereinthe closure member is made from a hook and loop closure.
 12. Thetemporary duct cover as recited in claim 1, wherein the filtrationportion is made from fabric having values of greater than approximately500 g of breathability.
 13. The temporary duct cover as recited in claim1, wherein the filtration portion is made from fabric having values ofless than approximately 20,000 mm of water resistance.
 14. A duct covercomprising: a filtration portion, the filtration portion made frommaterial which restricts the ingress of particulates into a duct,retards the ingress of moisture into the duct and allows the egress ofmoisture from the duct to inhibit the formation of mold in the duct, thefiltration portion having an open end and a closed end; a closure memberwhich is configured to conform to the duct, the closure member beingprovided at the open end of the filtration portion.
 15. The duct coveras recited in claim 14, wherein the filtration portion is made fromspunbond polypropylene.
 16. The duct cover as recited in claim 14,wherein the filtration portion is made from flash spun high-densitypolyethylene fibers.
 17. The duct cover as recited in claim 14, whereinthe filtration portion is made from bilaminate materials.
 18. The ductcover as recited in claim 16, wherein the closure member is made from anelasticized hem.
 19. A duct cover comprising: a filtration portion, thefiltration portion made from material which inhibits particulates largerthan 100 microns from passing through the filtration portion and thetemporary duct cover, the material having values of greater thanapproximately 500 g of breathability and values of less thanapproximately 20,000 mm of water resistance.
 20. The duct cover asrecited in claim 20, wherein a closure member is provided on the ductcover, the closure member is configured to conform to a duct, theclosure member being provided at an open end of the filtration portion.